JP2003191254A - Manufacturing method of artificial marble - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain an artificial marble having high design properties, a natural feel and a feel of high grade or having a granite pattern of high design properties. <P>SOLUTION: In the present manufacturing method of the artificial marble, a resin composition for molding the artificial marble is obtained by compounding additives such as a filler, a pattern material and a curing agent in a thermosetting resin and the artificial marble is manufactured by molding and curing the resin composition. The pattern material used for the artificial marble, which is compounded in this resin composition, is obtained by a process wherein one or more kinds of other pattern materials are added to and compounded in a pattern composition for the artificial marble, and the composition thus prepared is molded and cured and then crushed and classified. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an artificial marble used as a furniture member or a building material.

[0002]

2. Description of the Related Art Conventionally, an artificial marble molding resin composition containing a thermosetting resin and additives such as a filler, a handle, a reinforcing material, an internal release agent, and a curing agent has been used as a desired casting mold. It is known that an artificial marble is formed by injecting into and heat curing.

As a thermosetting resin which is a raw material for producing artificial marble, polyester resins, vinyl ester resins, acrylic resins and the like have been conventionally used.
Artificial marble moldings that make use of these are widely used in bathroom counters, kitchen counters, bathtubs, and washbasins.

[0004] Usually, in order to obtain an artificial marble product having a high design pattern or a granite pattern, it has been practiced to obtain an artificial marble molding resin composition containing several types of pattern materials having different shapes and color tones. However, at present, the pattern materials added and mixed have different color tones or different particle sizes,
In other words, the artificial marble molded product with a pattern material obtained is a combination of only changes in color and particle size, and the pattern pattern is very monotonous and hardly changes, giving it a natural or high-class appearance or high designability. There was a problem of lacking.

Therefore, at present, there is a strong demand for a method of manufacturing an artificial marble which has higher designability, natural feeling, high-class feeling or designability than the above-mentioned conventional examples.

[0006]

DISCLOSURE OF THE INVENTION The present invention has been made in view of the above-mentioned points, in which a pattern material for an artificial marble to be added to the resin composition for forming an artificial marble is mixed. By compounding and molding and curing, it is possible to obtain artificial marble with a granite pattern that has higher designability, natural feeling, high quality or high designability.
It is an object of the present invention to provide a method for producing artificial marble that does not reduce product strength.

[0007]

In order to solve the above problems, an artificial marble manufacturing method according to the present invention is an artificial marble molding in which a thermosetting resin is mixed with additives such as a filler, a pattern material, and a hardening agent. In the method for producing an artificial marble in which a resin composition for use is obtained and the artificial marble molding resin composition is molded and cured to produce an artificial marble, a pattern material for artificial marble to be blended with the artificial marble forming resin composition. As the above, a pattern material obtained by crushing and classifying a composition obtained by adding and mixing one or more kinds of different pattern materials to a pattern material composition for artificial marble and crushing and classifying it is used. . As described above, as a pattern material for artificial marble to be compounded and added to the resin composition for molding artificial marble, one or more kinds of pattern materials different from each other are mixed in the pattern material for artificial marble. Because of being used, the artificial marble obtained by molding and curing the resin composition for molding an artificial marble can be made into a granite pattern having higher designability, natural feeling, high-grade feeling or designability.

Further, the pattern material mixed in the pattern material composition and the pattern material for artificial marble obtained by mixing the pattern material have different color tones.
It is preferable that at least one or more pattern constituent elements are different in transparency or pattern pattern. By adopting such a method, it is possible to obtain a granit pattern which is more varied and has a high designability, a natural feeling, a high-class feeling or a high designability.

Another pattern material composition may be added as a pattern material to be added to the pattern material composition for artificial marble to obtain a pattern material for artificial marble which is mixed with the resin composition for molding artificial marble. It is preferable to use a pattern material obtained by repeating addition and blending of another pattern material, molding and curing, and crushing and classification once or more. By adopting such a method, in obtaining another one or more kinds of pattern materials mixed in the pattern material for artificial marble, the same step as that for obtaining the pattern material for artificial marble is performed once. It can be easily obtained by repeating the above.

Further, it is preferable that the handle material added to the handle material composition for artificial marble has an average thickness of 0.1 to 5.0 mm and an average particle diameter of 1.0 mm or more. By adopting such a method, the dispersibility between the pattern materials is good, the product strength does not decrease, and the expression in the pattern material can be made conspicuous.

Further, it is preferable that the shape of the handle material added and blended into the handle material composition for artificial marble is a single particle shape, a flat shape alone, or a mixture of a particle shape and a flat shape. By adopting such a method, various patterns can be expressed.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described below based on the embodiments shown in the accompanying drawings.

The method for producing an artificial marble of the present invention is to obtain a resin composition for artificial marble molding in which a thermosetting resin is mixed with additives such as a filler, a pattern material and a curing agent, and the resin for artificial marble molding is obtained. As a pattern material for artificial marble, which is blended with the resin composition for molding artificial marble when the composition is molded and cured to produce artificial marble, one or more different pattern materials are added to the pattern material composition for artificial marble. A pattern material obtained by pulverizing and classifying a mixture obtained by adding and compounding and curing the mixture is used. In this way, the artificial marble resin composition obtained by pulverizing and classifying the mixture obtained by adding and blending one or more different pattern materials and curing the mixture is compounded with the artificial marble resin composition. An artificial marble molded article having a granite pattern is obtained by injecting the molding resin composition into a desired casting mold and heating and curing.

One or more kinds of pattern materials added to and compounded with the pattern material for artificial marble to be mixed with the resin composition for molding artificial marble can be obtained by the flow shown in FIG.

First, as the first stage, (1) to (1) of FIG.
As shown in (4), different colorants are used (colorant a, colorant b, colorant c, colorant d ...), that is, resin compositions for pattern materials having different color tones are formed into a plate or sheet. Shaped and hardened, and crushed and classified into a certain particle size range, and the pattern material a, the pattern material b, the pattern material c, the pattern material d ...
Get ...

Next, as the second stage, (5) to (1) of FIG.
As shown in (8), these pattern materials a, b, c, d ... Are combined with the colorant and the compounding amount set to match the intended pattern. , Colorant A
, Pattern material a, pattern material c, pattern material d ..., Colorant B and pattern material a, pattern material b, pattern material c, ..., Colorant C, pattern material b, pattern material c, the combination with the pattern material d ..., etc.) to obtain a resin composition for a pattern material, and further, the resin composition for a pattern material is molded and cured into a plate-like or sheet-like shape as described above. Then, the material is pulverized and classified into a certain particle size range to obtain the following pattern material A, pattern material B, pattern material C ....

Next, as a third step, as shown in FIG. 1 (9), one or more kinds of the pattern material A, the pattern material B, the pattern material C ... Are used as a pattern material for artificial marble. With the combination of the blending amount and the colorant set to match the pattern of
An artificial marble molding resin composition containing a handle is obtained.

Next, as the fourth stage, (10) to (1) of FIG.
As shown in (12), an artificial marble molded article having a granite pattern is obtained by injecting the above-mentioned resin composition for artificial marble molding containing a pattern material into a desired casting mold and curing by heating. .

Here, in the present invention, the above (5)-
By repeating the operation of (8) a plurality of times, the pattern material can be further changed. That is, the pattern material A, the pattern material B, and the pattern material C of (8) become a part of the combination of the pattern materials of (5), and the operations of (5) to (8) are sequentially repeated once or more. It will be done.

In addition, one or more types of pattern materials for artificial marble have different kinds and addition amounts of colorants, kinds and blending ratios of resin and filler, or the degree of repetition of the above operations (5) to (8). Depending on the color tone, transparency, or pattern, each grain is very different and very varied. FIG. 2 shows an example of an artificial marble molded product 1 having a granite pattern according to the present invention. In FIG. 2, 2 is a pattern material A, 3 is a pattern material B, 4 is a pattern material C, 5 is a pattern material D, and 6 is a pattern material E. In addition, FIG. 3 shows an example of a pattern material (illustrated as pattern material A) for artificial marble mixed in an artificial marble molded product, 7 is pattern material a, and 8 is pattern material b. 9 shows the handle c, 10 shows the handle d, and 11 shows the handle e.

In the present invention, the pattern material for artificial marble having this change has an average thickness of 0.1 to 5.0 mm and an average particle size of 1.0 mm or more.

Here, when the average thickness is 0.1 mm or less, the pattern material for artificial marble becomes too thin and the sticking of pattern materials for artificial marble becomes severe, so that the pattern material for artificial marble in the resin composition for artificial marble molding. The dispersibility is extremely deteriorated, the desired pattern expression cannot be obtained, and the product strength is lowered, which is not preferable. On the other hand, if the average thickness exceeds 5.0 mm, the pattern materials for artificial marble do not stick to each other, but the dispersibility deteriorates and the product strength is deteriorated similarly to the above, which is not preferable. Further, the reason why the average particle diameter is set to 1.0 mm or more is that the expression in the pattern material for artificial marble, which is rich in the change, is not conspicuous unless it becomes 1.0 mm or more. That is, the pattern expression of the present invention cannot be obtained with a pattern material for artificial marble having an average particle size of 1.0 mm or less.

Further, if a pattern material for artificial marble or a pattern material mixed in a pattern material for artificial marble, which has been previously subjected to a coupling treatment, is used as a pattern material for artificial marble, a resin and a pattern material. The adhesiveness with a resin can be improved and the impact resistance strength of the artificial marble product can be improved.

The shape of the pattern material for artificial marble, or the shape of the pattern material mixed in the pattern material for artificial marble, may be a granular shape (spherical shape) or a flat shape depending on the manufacturing method and crushing conditions. can get. In the present invention, these may be used alone or in the form of a mixture by adding and blending.

Thermosetting resin of resin composition constituting pattern material, pattern material for artificial marble, and thermosetting resin constituting artificial marble molding resin composition obtained by adding pattern material for artificial marble It is preferable to use the same type of resin as the resin, and the thermosetting resin may be polyester resin, vinyl ester resin,
The acrylic resin may be used alone or in a mixture of two or more of these.

The polyester resin is a thermosetting resin, which is synthesized by subjecting an unsaturated dibasic acid such as maleic anhydride and a saturated dibasic acid such as phthalic anhydride to a condensation reaction with glycols to form an intramolecular compound. It has an unsaturated bond and an ester bond. Usually, a styrene monomer, an acrylic monomer, etc. are blended as a cross-linking agent in this resin, and a so-called unsaturated polyester resin is used, but its form is not particularly limited.

The vinyl ester resin may be a bisphenol type vinyl ester resin, a novolac type vinyl ester resin, or a mixture of both.

Here, the bisphenol type vinyl ester resin is an addition reaction product of a bisphenol type epoxy resin and an acid, and each has a reactive unsaturated group only at both ends. Further, as the bisphenol type epoxy resin, bisphenol A type, bisphenol AD
Type, bisphenol S type, bisphenol F type and the like can be used. Further, a styrene monomer, an acrylic monomer, etc. are usually blended in the vinyl ester resin as a cross-linking agent, but the form is not particularly limited.

As the acrylic resin, what is called a thermosetting type acrylic syrup usually composed of a methylmethacrylate monomer, a polyfunctional acrylic monomer, a prepolymer, or a mixture of two or more kinds of polymers. However, the form is not particularly limited.

When a mixture of two or more kinds of polyester resin, vinyl ester resin, and acrylic resin is used, the purpose is to be determined by the characteristics of each resin and the interaction with the filler or the additive compound. The optimum blending that matches the product quality is required, but the blending amount is not particularly limited.

The filler is aluminum hydroxide, silica,
It can be used as one kind of glass powder or a mixture of two or more kinds. The blending amount of the filler is
The amount is preferably 100 to 300 parts by weight with respect to 100 parts by weight of the thermosetting resin. If the amount is less than this range, the impact resistance of the product is excellent, but the heat resistance may not be sufficiently exhibited. If it exceeds the range, the heat resistance is excellent, but the impact strength may decrease. However, this is not a limitation.

The smaller the particle size of the filler is, the more the impact strength of the artificial marble product can be improved, but the viscosity of the resin composition sharply increases, which tends to make the production difficult. When the particle size of the filler becomes large, the clay of the resin composition for artificial marble molding decreases and the problems in the production disappear, but the impact resistance strength of the artificial marble product tends to decrease, so the average particle size Is preferably in the range of 5 μm to 50 μm. However, this is not particularly limited.

If a filler having a silane coupling treatment on its surface is used, the adhesiveness between the filler and the resin can be improved and the impact resistance of the artificial marble product can be improved. It is a thing.

Further, a curing agent is added to the artificial marble molding resin composition.

As the curing agent, 1,1,3,3-tetramethylbutylperoxy-2-ethylhexanoate or t-hexylperoxy-2-ethylhexanoate can be used. For example, in the case of a vinyl ester resin, the mixing ratio of this curing agent is 1 total amount of the resin and the crosslinking agent.
It is preferably 0.5 to 5 parts by weight with respect to 00 parts by weight.

Further, the artificial marble molding resin composition may be blended with an ultraviolet absorber, a viscosity reducing agent, a release agent, a glass fiber and a coloring agent.

The resin composition for pattern material or the resin composition for artificial marble molding is prepared by mixing these compounds containing the pattern material or the pattern material for artificial marble molding at a predetermined ratio and mixing and stirring with a stirrer or the like. Mix and prepare.

In producing artificial marble from the artificial marble molding resin composition, the blended and prepared artificial marble molding resin composition is subjected to vacuum defoaming treatment under a reduced pressure of about 20 to 50 Torr and released from the reduced pressure state. And wait for the molding and curing.

The resin composition for pattern material thus obtained is poured into a plate-shaped or sheet-shaped molding die, and
The artificial marble molding resin composition is poured into a mold having a predetermined shape, and these molds or molds are heated at a temperature of 50 to 110 ° C. for 30 to 120 minutes.

By heating, the reactive unsaturated group in the resin composition for pattern material or the resin composition for artificial marble molding and the copolymerization reaction of the polymerizable monomer in the resin are allowed to proceed to thereby advance the pattern material. The resin composition for molding or the resin composition for artificial marble molding is cured and molded.

The artificial marble molded article containing the pattern material for artificial marble of the present invention obtained as described above is different from the pattern material itself for artificial marble in color tone, transparency or pattern pattern, and changes. As it is composed of abundant materials, it is possible to obtain artificial marble with a granite pattern that has higher designability, naturalness, high-class feel and design than conventional ones, and also reduces product strength. It is possible to obtain an artificial marble that does not cause it.

Such an artificial marble molded product can be easily commercialized as a wash counter, a kitchen counter, a bathtub, a wash ball, or a floor material or a surface material of furniture.

[0043]

EXAMPLES The present invention will be described in detail below with reference to examples. (Example 1) A polyester resin (Prominate P-311 manufactured by Takeda Pharmaceutical Co., Ltd.) was used as a thermosetting resin, and aluminum hydroxide (Showa Denko KK) was used as a filler.
H-308B (average particle size: 8 μm) prepared by changing the compounding ratio and adding a colorant (toner) to each (unit: parts by weight), that is, (a) = resin / filler / colorant. = 100/50 / black toner 0.2 (b) = resin / filler / colorant = 100/100 / brown toner 0.25 (c) = resin / filler / colorant = 100/150 / white toner 0.2 (d) = resin / filler / colorant = 100/200 / gray toner 0.15 4 kinds of resin compositions for pattern materials were prepared. Further, 2.0 parts by weight of a curing agent (Percure HO manufactured by NOF CORPORATION) was added to each of them, and the mixture was stirred and mixed under a vacuum defoaming treatment under a reduced pressure of 20 Torr for 60 minutes.
It is poured into a die to be formed into a sheet having a thickness of 5 mm, heated at a die temperature of 100 ° C. for 30 minutes to be hardened, crushed by a crusher and classified, and the pattern material a, the pattern material b, and the pattern material in FIG. c,
A pattern material d was obtained. Next, (A) = resin composition (a) / pattern material b / pattern material c / pattern material d in the resin composition for a pattern material of (a), (b) and (c) (unit is parts by weight). =
100 / 1.5 / 5.0 / 3.0 (B) = resin composition (b) / pattern material a / pattern material c / pattern material d =
100 / 1.0 / 5.0 / 2.0 (C) = resin composition (c) / pattern material a / pattern material b / pattern material d =
Three types of resin compositions for handle materials of 100 / 1.5 / 7.0 / 1.5 were prepared. Further, 2.0 parts by weight of a curing agent (Percure HO manufactured by NOF CORPORATION) was added to each of them, and the mixture was stirred and mixed under a vacuum defoaming treatment under a reduced pressure of 20 Torr for 60 minutes.
It is poured into a mold for forming a sheet with a thickness of 7 mm and a mold for forming a plate with a thickness of 5 mm, heated at a mold temperature of 100 ° C. for 40 minutes to cure, and crushed with a crusher for classification.
The pattern material A, the pattern material B, and the pattern material C of FIG. 1 having an average particle size of 1.0 to 4.0 mm, and the flat pattern material A ′ and the pattern material having an average particle size of 1.0 to 5.0 mm. B ′ and a pattern material C ′ were obtained.

Next, the resin composition for pattern material of the above (c) is used as a resin composition for artificial marble molding, and the pattern material A, the pattern material B, the pattern material C, the pattern material A ', and the pattern material. B'and the pattern material C'are used as a pattern material for artificial marble, and the pattern material A is used as the resin composition for pattern material of (c) used as a resin composition for artificial marble molding.
= 1.5 parts by weight, pattern material B = 2.5 parts by weight, pattern material C = 3.
0 parts by weight, pattern material A '= 1.0 parts by weight, pattern material B' = 1.5
A resin composition for artificial marble containing a pattern material for artificial marble was prepared by mixing 1 part by weight and a pattern material C ′ = 1.0 part by weight. Furthermore,
Hardener (Percure HO manufactured by NOF CORPORATION) 2.0
Parts by weight were added, and this was stirred and mixed under a vacuum defoaming treatment under a reduced pressure of 20 Torr for 60 minutes, and then mixed in a predetermined shape 11
It was poured into a casting mold set to a thickness of mm and heated at a mold temperature of 100 ° C. for 110 minutes to be cured, and a pattern material for a multicolor artificial marble having a shape as shown in FIG. An artificial marble molded product having a granite pattern was obtained. Example 2 A polyester resin (Polymer 5450 manufactured by Takeda Pharmaceutical Co., Ltd.) was used as the thermosetting resin, and aluminum hydroxide (H-310 average particle size 17 μm manufactured by Showa Denko KK) was used as the filler. By adding the colorant (toner) to each of them (unit: parts by weight), that is, (a) = resin / filler / colorant = 100/80 / brown toner 0.5 (B) = resin / filler / colorant = 100/120 / beige toner 0.4 (c) = resin / filler / colorant = 100/160 / black toner 0.2 (d) = resin / filler Agent / colorant = 100/200 / white toner 0.2 4 types of resin compositions for pattern materials were prepared. Further, 2.0 parts by weight of a curing agent (Percure HO manufactured by NOF CORPORATION) was added to each of them, and the mixture was stirred and mixed under a vacuum defoaming treatment under a reduced pressure of 20 Torr for 60 minutes, and then 1.
It is poured into a mold to be molded into a sheet having a thickness of 0 mm, heated at a mold temperature of 100 ° C. for 30 minutes to be hardened, crushed by a crusher and classified, and the pattern material a, the pattern material b, and the pattern material of FIG. c,
A pattern material d was obtained. Next, (A) = resin composition (a) / pattern material b / pattern material c / pattern material d in the resin composition for a pattern material of (a), (b) and (c) (unit is parts by weight). =
100 / 2.0 / 1.0 / 1.0 (B) = resin composition (b) / pattern material a / pattern material c / pattern material d =
100 / 5.0 / 1.5 / 2.0 (C) = resin composition (c) / pattern material a / pattern material b / pattern material d =
Three kinds of resin compositions for handle materials of 100 / 3.5 / 7.0 / 1.0 were prepared. Further, 2.0 parts by weight of a curing agent (Percure HO manufactured by NOF CORPORATION) was added to each of them, and the mixture was stirred and mixed under a vacuum defoaming treatment under a reduced pressure of 20 Torr for 60 minutes. Mold for forming a sheet with a thickness of 6 mm and 4 m
It is poured into a m-thick plate mold and the mold temperature is 100
The mixture is heated at 40 ° C. for 40 minutes to be hardened, crushed by a crusher and classified, and the pattern material A, the pattern material B, the pattern material C and the average particle size of FIG. 1.0 to 5.0 m
m flat pattern material A ′, pattern material B ′, and pattern material C ′ were obtained.

Next, the resin composition for pattern material of (d) above is used as a resin composition for artificial marble molding, and the above pattern material A, pattern material B, pattern material C, pattern material A ', pattern material B'and the pattern material C'are used as a pattern material for artificial marble, and the pattern material A is used in the resin composition for pattern material of (d) used as a resin composition for artificial marble molding.
= 1.0 part by weight, pattern material B = 2.0 parts by weight, pattern material C = 3.
0 parts by weight, pattern material A '= 2.0 parts by weight, pattern material B' = 1.0
A resin composition for an artificial marble containing a pattern material for an artificial marble was prepared by blending parts by weight and the pattern material C ′ = 2.0 parts by weight. Furthermore,
Hardener (Percure HO manufactured by NOF CORPORATION) 2.0
By weight, this was added under a reduced pressure of 20 Torr for 60 minutes under vacuum defoaming treatment while stirring and mixing, and then 12
It was poured into a casting mold set to a thickness of mm and heated at a mold temperature of 100 ° C. for 100 minutes to be cured, and a pattern material for a multicolor artificial marble having a shape as shown in FIG. An artificial marble molded product having a granite pattern was obtained. (Example 3) Acrylic syrup resin (AC-02 manufactured by Nippon Fellow Co., Ltd.) was used as a thermosetting resin, and silica (CRYSTALI manufactured by Tatsumori Co., Ltd.) was used as a filler.
TEM-3K average particle size 20 μm), the compounding ratio was changed, and the colorant (toner) was added to each (unit is part by weight), that is, (a) = resin / filler / colorant = 100/80 / brown toner 0.45 (b) = resin / filler / colorant = 100/100 / beige toner 0.35 (c) = resin / filler / colorant = 100/120 / white toner 0.3 (d) = resin / filler / colorant = 100/150 / black toner 0.3 4 types of resin compositions for pattern materials were prepared. In addition, a curing agent (Kayaku Akzo Co., Ltd.
6) was added by 1.8 parts by weight, and the mixture was stirred and mixed under a reduced pressure of 20 Torr for 30 minutes while performing vacuum defoaming treatment, and then poured into a mold for forming a 0.8 mm-thick sheet, Heat at 80 ° C. for 30 minutes to cure, crush with a crusher and classify.
Pattern material c and pattern material d were obtained. Next, the above (a) and (b)
(C) (Unit is parts by weight) (A) = resin composition (a) / pattern material b / pattern material c / pattern material d =
100 / 2.5 / 2.5 / 1.5 (B) = resin composition (b) / pattern material a / pattern material c / pattern material d =
100 / 4.0 / 1.5 / 2.5 (C) = resin composition (c) / pattern material a / pattern material b / pattern material d =
Three types of resin compositions for handle materials of 100 / 2.5 / 8.0 / 1.0 were prepared. In addition, a curing agent (Kayaku Akzo Co., Ltd.
6) was added in an amount of 1.8 parts by weight, and the mixture was stirred and mixed under reduced pressure of 20 Torr for 60 minutes while performing vacuum defoaming treatment, and then each was molded into a sheet having a thickness of 0.6 mm and a die having a thickness of 4 mm. It is poured into a plate-shaped mold, heated at a mold temperature of 80 ° C. for 40 minutes to be cured, crushed by a crusher and classified, and the average particle size is 1.0 to 4.0 mm.
Pattern material A, pattern material B, pattern material C, and an average particle size of 1.0 to
4.0 mm flat pattern material A ', pattern material B', and pattern material C'were obtained.

Next, the resin composition for pattern material of the above (c) is used as a resin composition for artificial marble molding, and the above pattern material A, pattern material B, pattern material C, pattern material A ′, pattern material B'and the pattern material C'are used as a pattern material for artificial marble, and the pattern material A is used as the resin composition for pattern material of (c) used as a resin composition for artificial marble molding.
= 1.0 part by weight, pattern material B = 2.0 parts by weight, pattern material C = 3.
0 parts by weight, pattern material A '= 2.0 parts by weight, pattern material B' = 1.0
A resin composition for an artificial marble containing a pattern material for an artificial marble was prepared by blending parts by weight and the pattern material C ′ = 2.0 parts by weight. Furthermore,
2.0 parts by weight of a curing agent (Perkadox 16 manufactured by Kayaku Akzo Co., Ltd.) was added, and the mixture was added under reduced pressure of 20 Torr to 6
After stirring and mixing for 0 minutes under vacuum defoaming treatment, the mixture is poured into a casting mold having a predetermined shape and a thickness of 12 mm, and the mold temperature is heated at 85 ° C. for 100 minutes to be cured, as shown in FIG. A granite-patterned artificial marble molded product containing a pattern material for a multicolored artificial marble having various shapes was obtained. (Example 4) As a thermosetting resin, vinyl ester (Lipoxy R-804 manufactured by Showa Highpolymer Co., Ltd.) and polyester resin (Polymer 5250 manufactured by Takeda Pharmaceutical Co., Ltd.) were mixed at a mixing ratio of 80/20. Aluminum hydroxide as a filler (H-3 manufactured by Showa Denko KK)
20 average particle diameter 10 μm) and glass powder (manufactured by Nippon Frit Co., Ltd. GF-2-30A average particle diameter 30 μm)
Which are mixed at a mixing ratio of 90/10, the mixing ratio is changed, and a colorant (toner) is added to each (unit is part by weight), that is, (a) = resin / filler / coloring Agent = 100/80 / brown toner 0.5 (b) = resin / filler / colorant = 100/110 / beige toner 0.3 (c) = resin / filler / colorant = 100/140 / Black toner 0.5 (d) = resin / filler / colorant = 100/170 / white toner 0.2 4 types of resin compositions for pattern materials were prepared. Furthermore, 3.0 parts by weight of a curing agent (Percure HO manufactured by NOF CORPORATION) was added to each of them, and the mixture was stirred and mixed under vacuum degassing treatment for 30 minutes under a reduced pressure of 20 Torr.
It is poured into a die to be molded into a sheet having a thickness of 8 mm, heated at a die temperature of 95 ° C. for 30 minutes to be hardened, crushed by a crusher and classified, and the pattern material a, the pattern material b, and the pattern material in FIG. c and the pattern material d were obtained. Next, (A) = resin composition (a) / pattern material b / pattern material c / pattern material d in the resin composition for a pattern material of (a), (b) and (c) (unit is parts by weight). =
100 / 3.0 / 2.5 / 1.0 (B) = resin composition (b) / pattern material a / pattern material c / pattern material d =
100 / 3.0 / 1.5 / 2.0 (C) = resin composition (c) / pattern material a / pattern material b / pattern material d =
Three kinds of resin compositions for handle materials of 100 / 3.5 / 5.0 / 2.5 were prepared. Further, 3.0 parts by weight of a curing agent (Percure HO manufactured by NOF CORPORATION) was added to each of them, and the mixture was stirred and mixed under a vacuum defoaming treatment under a reduced pressure of 20 Torr for 60 minutes. Mold for forming a sheet with a thickness of 7 mm and 5 m
It is poured into a metal mold to be molded into a m-thick plate, and the mold temperature is 95 ° C.
At 40 ° C. for 40 minutes for curing, crushing with a crusher for classification, and pattern material A, pattern material B, pattern material C of FIG. 1 having an average particle size of 1.0 to 4.0 mm, and an average particle size of 1 .0-5.0m
m flat pattern material A ′, pattern material B ′, and pattern material C ′ were obtained.

Next, the above-mentioned resin composition for a pattern material (d) is used as a resin composition for forming an artificial marble, and the pattern material A, the pattern material B, the pattern material C, the pattern material A ', and the pattern material. B'and the pattern material C'are used as a pattern material for artificial marble, and the pattern material A is used in the resin composition for pattern material of (d) used as a resin composition for artificial marble molding.
= 1.5 parts by weight, pattern material B = 2.0 parts by weight, pattern material C = 2.
5 parts by weight, handle material A '= 2.0 parts by weight, handle material B' = 3.0
The resin composition for artificial marble with a pattern material for artificial marble was prepared by mixing 1 part by weight and C '= 1.5 parts by weight. Furthermore,
Hardener (Nippon Yushi Co., Ltd. Percure HO) 3.0
Parts by weight were added, and this was stirred and mixed under a vacuum defoaming treatment under a reduced pressure of 20 Torr for 60 minutes, and then mixed in a predetermined shape 11
It was poured into a casting mold set to a thickness of mm and heated at a mold temperature of 95 ° C. for 100 minutes to be cured, and a pattern material for a multicolor artificial marble having a shape as shown in FIG. An artificial marble molded product having a granite pattern was obtained. (Example 5) As thermosetting resins, vinyl ester (Showa High Polymer Co., Ltd. Lipoxy R-804) and acrylic syrup (Mitsui Chemicals Co., Ltd. XE924-1) were used.
Aluminum hydroxide (H-320 manufactured by Showa Denko KK) was used as a filler.
The average particle size is 10 μm), the compounding ratio is changed, and the colorant (toner) is added to each (unit is part by weight), that is, (a) = resin / filler / colorant = 100/90 / Brown toner 0.4 (b) = resin / filler / colorant = 100/120 / beige toner 0.35 (c) = resin / filler / colorant = 100/150 / white toner 0.6 ( d) = resin / filler / colorant = 100/180 / black toner 0.25 4 kinds of resin compositions for pattern materials were prepared. Furthermore, 3.0 parts by weight of a curing agent (Percure HO manufactured by NOF CORPORATION) was added to each of them, and the mixture was stirred and mixed under vacuum degassing treatment for 30 minutes under a reduced pressure of 20 Torr.
It is poured into a die to be molded into a sheet having a thickness of 8 mm, heated at a die temperature of 95 ° C. for 30 minutes to be hardened, crushed by a crusher and classified, and the pattern material a, the pattern material b, and the pattern material in FIG. c and the pattern material d were obtained. Next, (A) = resin composition (a) / pattern material b / pattern material c / pattern material d in the resin composition for a pattern material of (a), (b) and (c) (unit is parts by weight). =
100 / 3.5 / 2.5 / 1.5 (B) = resin composition (b) / pattern material a / pattern material c / pattern material d =
100 / 3.0 / 2.0 / 1.0 (C) = resin composition (c) / pattern material a / pattern material b / pattern material d =
Three types of resin compositions for handle materials of 100 / 2.5 / 5.5 / 2.5 were prepared. Further, 3.0 parts by weight of a curing agent (Percure HO manufactured by NOF CORPORATION) was added to each of them, and the mixture was stirred and mixed under a vacuum defoaming treatment under a reduced pressure of 20 Torr for 60 minutes. It is poured into a mold to be formed into a sheet having a thickness of 85 mm, and the mold temperature is heated at 95 ° C. for 25 minutes to cure,
The crusher was crushed and classified, and the pattern material a, the pattern material b, the pattern material c, the pattern material d = the pattern material a ′, the pattern material b ′, the pattern material c ′, and the pattern material d ′ in FIG. 1 were obtained again. . Furthermore, the above (a) and (b)
In the resin composition for a pattern material of (c) (unit is parts by weight), (A) '= resin composition (a) / pattern material b' / pattern material c '/ pattern material d' = 100 / 2.5 /1.5/1.5 (B) '= resin composition (b) / pattern material a' / pattern material c '/ pattern material d' = 100 / 2.5 / 1.0 / 2.0 (C ) '= Resin composition (c) / pattern material a' / pattern material b '/ pattern material d' = 100/3. 0 / 4.0 / 3.0 Three types of resin compositions for pattern materials are prepared. did. Further, 3.0 parts by weight of a curing agent (Percure HO manufactured by NOF CORPORATION) was added to each of them, and the mixture was stirred and mixed under a vacuum defoaming treatment under a reduced pressure of 20 Torr for 60 minutes. Mold for forming a sheet with a thickness of 7 mm and 5 m
It is poured into a metal mold to be molded into a m-thick plate and the mold temperature is 95 ° C.
At 40 ° C. for 40 minutes to harden, crush with a crusher and classify, and the average particle size is 1.0 to 4.0 mm. The pattern material A ′, the pattern material B ′, the pattern material C ′, and the average particle size. Is 1.0-
5.0 mm flat pattern material A ″, pattern material B ″, and pattern material C ″ were obtained.

Next, the resin composition for pattern material of the above (a) is used as a resin composition for artificial marble molding, and the above pattern material A ', pattern material B', pattern material C ', pattern material A ". , Pattern material B ″, and pattern material C ″ are used as a pattern material for artificial marble, and the pattern material A ′ is 1.5 parts by weight in the resin composition for pattern material of (a) used as a resin composition for artificial marble molding. Pattern material B ′ = 3.5 parts by weight, pattern material C ′ = 1.0 parts by weight, pattern material A ″ = 2.0 parts by weight, pattern material B ″ = 2.0 parts by weight, pattern material C ″ = 2.5 parts by weight were mixed to prepare a resin composition for artificial marble with a pattern material for artificial marble. In addition, a curing agent (Percure H manufactured by NOF CORPORATION)
O) is added in an amount of 3.0 parts by weight, and the mixture is stirred and mixed under a reduced pressure of 20 Torr for 60 minutes while performing vacuum defoaming treatment, and then poured into a casting mold set to have a predetermined shape and a thickness of 12 mm. The mold was heated at 95 ° C. for 100 minutes to be cured, and a granite-patterned artificial marble molded product containing a pattern material for multicolored artificial marble having a form as shown in FIG. 2 was obtained.

[0049]

As described above, in the invention of claim 1 of the present invention, as a pattern material for artificial marble to be blended with the resin composition for molding artificial marble, a pattern material composition for artificial marble. Since the pattern material obtained by pulverizing and classifying a mixture obtained by adding and blending one or more different pattern materials to and molding and hardening is used in the pattern material for artificial marble, one or more other pattern materials are used. It is possible to produce an artificial marble having a granite pattern having a high designability, a natural feeling, a high-class feeling, or a high designability because it is mixed with a variety of materials.

In addition to the effect of the invention described in claim 1, the invention described in claim 2 is obtained by mixing a pattern material mixed in the pattern material composition and the pattern material. Since the pattern material for artificial marble differs in at least one or more pattern constituent elements among color tone, transparency, and pattern,
The pattern material for artificial marble is rich in variations, and as a result, a granite pattern having a high designability, a natural feeling, a high-class feeling, or a high designability can be obtained.

Further, in the invention of claim 3, in addition to the effect of the invention of claim 1 or claim 2, a handle material for artificial marble to be blended with the resin composition for artificial marble molding. As a pattern material to be added and compounded to a pattern material composition for artificial marble for obtaining, a pattern material is added and compounded to another pattern material composition, and the mixture is molded and cured, and pulverized and classified once or more. Since the obtained pattern material is used, in order to obtain one or more kinds of pattern materials mixed in the pattern material for artificial marble, the same process as that for obtaining the pattern material for artificial marble is performed once. It can be easily obtained by repeating the above.

Further, in the invention of claim 4, in addition to the effect of the invention of any one of claims 1 to 3, a handle added to a handle material composition for artificial marble is added. The material has an average thickness of 0.1 to 5.0 mm and an average particle size of 1.0
Since it is more than mm, the dispersibility between the pattern materials is good and the product strength is not deteriorated, and the expression in the pattern material can be made conspicuous. It is possible to make a granit pattern with high design.

In addition, in the invention of claim 5, in addition to the effect of the invention of any one of claims 1 to 4, a handle added to the handle material composition for artificial marble. Since the shape of the material is a single particle shape, a flat shape alone, or a mixture of particle size and flat shape, it is possible to express a variety of pattern materials, and to further enhance designability, natural feeling, and high-class feeling. Alternatively, a granit pattern having a high design property can be obtained.

[Brief description of drawings]

FIG. 1 is a flow chart showing a manufacturing sequence of a method for manufacturing an artificial marble of the present invention.

FIG. 2 is a perspective view showing an example of an artificial marble molded product obtained by the present invention.

FIG. 3 is an explanatory view showing the details of a pattern material for artificial marble of the same.

[Explanation of symbols]

1 Artificial marble molding

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Shinji Yamaguchi             18 18-1 Aze, Wakamatsu-ku, Kitakyushu, Fukuoka               Kitakyushu Matsushita Electric Works Co., Ltd. F-term (reference) 4F204 AA41 AB03 AB11 AB12 AB16                       AC01 AH44 EA03 EB01 EB28                       EE12 EF01 EF02 EK13 EK17

Claims (5)

[Claims] 1. An artificial marble molding resin composition obtained by mixing a thermosetting resin with an additive such as a filler, a handle, and a curing agent, and molding and curing the artificial marble molding resin composition to manufacture the artificial marble molding resin composition. In the manufacturing method of artificial marble for manufacturing marble,
As a pattern material for artificial marble to be blended with the resin composition for molding artificial marble, one obtained by adding and blending one or more different pattern materials to the pattern material composition for artificial marble, crushed and classified. A method for producing artificial marble, characterized in that the obtained pattern material is used. 2. A pattern material blended in a pattern material composition and a pattern material for artificial marble obtained by mixing the pattern material have at least one of color tone, transparency or pattern. The method of manufacturing an artificial marble according to claim 1, wherein the pattern constituent elements are different. 3. Another pattern material composition is added as a pattern material to be added to a pattern material composition for artificial marble to obtain a pattern material for artificial marble, which is mixed with the resin composition for molding artificial marble. The method for producing an artificial marble according to claim 1 or 2, characterized in that a pattern material obtained by repeating one or more times of adding and mixing another pattern material, molding and curing, and pulverizing and classifying is used. 4. The pattern material added to the pattern material composition for artificial marble has an average thickness of 0.1 to 5.0 mm and an average particle size of 1.0 mm or more. The method for manufacturing an artificial marble according to claim 3. 5. The shape of the pattern material added and blended into the pattern material composition for artificial marble is a particle shape alone, a flat shape alone, or a mixture of a particle size shape and a flat shape. 5. The method for manufacturing an artificial marble according to claim 4.